Selective precipitation of α-aryl carboxylic acid salts

ABSTRACT

A process is provided whereby S(+)-ibuprofen or R(-)-ibuprofen L-lysinate salt is produced by selective precipitation from a mixture containing enantiomers of ibuprofen and L-lysine. The quantity of L-lysine is not more than about a molar equivalent of the quantity of one of the enantiomers in the ibuprofen enantiomeric mixture. Upon precipitation of one ibuprofen enantiomer from the mixture, the overall precipitate and reaction mixture can be held for a sufficient period of time at a second temperature to allow the first precipitate to redissolve into the reaction mixture and the other ibuprofen enantiomer to precipitate out of the mixture in the salt form. Optically active ibuprofen is racemized by being heated at 100° C. to 300° C. in the substantial absence of other materials.

RELATED APPLICATIONS

This is a continuation application of application Ser. No. 08/139,245,filed Oct. 19,1993, which is a continuation-in-part application ofpatent application Ser. No. 07/985,083, filed Dec. 2, 1992, now U.S.Pat. No. 5,332,834.

FIELD OF THE INVENTION

The present invention relates to selective crystallization of thedesired salt of an α-aryl carboxylic acid from a mixture containing anα-aryl carboxylic acid and a suitable amino acid. By appropriate choiceof the amounts of reactants, time, and temperature, the process enablesselective crystallization of the desired diastereomer salt. Repetitionof various facets of this process affords high yields of the desiredsalt in good enantiomeric excess, which may then be optionally acidifiedto afford optically active α-aryl carboxylic acid.

BACKGROUND OF THE INVENTION

α-Aryl carboxylic acids are well known non-steroidal anti-inflammatory(NSAI) drugs. An example is ibuprofen (Formula 1) which is typically aracemic mixture of the S(+)- and R(-)-enantiomers. ##STR1##

Studies have indicated that the S(+)-isomer is more pharmacologicallyactive than the R(-)-isomer, see, for Example, A. Avgerinos et al,Chirality, Vol. 2, 249 (1990). Attempts have been made recently toisolate the S(+)-isomer from the racemic mixture.

U.S. Pat. No. 5,015,764 (Assignee: Ethyl Corp.) discloses a processwhereby the triethylamine salt of racemic ibuprofen is treated withchiral α-methyl-benzylamine (MBA). The MBA salt of one isomer ofibuprofen separates as crystals and is filtered off. The triethylaminesalt of the other isomer is isolated from the filtrates, is separatelyracemized, and is then treated again as described above.

U.S. Pat. No. 4,994,604 (Assignee: Merck & Co.) teaches S-lysine for theresolution of racemic ibuprofen. Racemic ibuprofen and S-lysine arecombined in equimolar quantities in a solvent system, such asethanol:water so that the solution is supersaturated in both R, S and S,S salts. The solution is first aged at around 30° C., and then seeded ataround 25° C. with a fairly large amount of S-ibuprofen-S-lysinate. Thisallows the S-ibuprofen-S-lysinate from the racemate mixture tocrystallize out. The mother liquor, after filtration, is seeded again toprecipitate additional S-salt. Repetition of this process gives theS-ibuprofen-S-lysinate as crystals, and leaves the R-salt in thesolution, thus allowing a recovery of 50% of the original amount of theracemic ibuprofen as S-ibuprofen lysinate salt.

U.S. Pat. No. 5,189,208 (Assignee: Ethyl Corporation) discloses aprocess for obtaining a substantially pure enantiomer of ibuprofen. Theprocess utilizes first an enantiomerically enriched mixture of ibuprofenobtained from kinetic resolution, diastereomeric crystallization, orasymmetric synthesis processes. This enriched mixture is dissolved in asolvent and solid racemic ibuprofen is separated, leaving a motherliquor comprising the solvent and the enriched enantiomer substantiallyfree of the other enantiomer.

Other prior art references which are pertinent include U.S. Pat. Nos.3,43 1,295; 4,752,417; 4,994,604; British Patent Specification No.899,023; and pending U.S. patent application Ser. No. 07/649,782, filedJan. 31, 1991 (A. Bhattacharya et al.).

All of these prior art references are submitted pursuant to 37 CFR 1.56,1.97, and 1.98. These references, patent applications, and patents areincorporated herein by reference in their entirety.

Other methods such as enzymatic resolution and chromatography have alsobeen suggested for resolution. The disadvantage with such processes isthat they are time-consuming, and the yields are low.

While resolution of racemic mixtures is known, generally such processeslead to yields of a maximum 50% of one isomer, and 50% of the otherisomer. In order to get higher yields of one isomer, the other isomer,after isolation, must be separately racemized to eventually isolate moreof the desired isomer. Such processes generally employ conditions thatare so different from the resolution step that the two are incompatiblefor efficient recycle. Because optically active α-aryl carboxylic acidsand their salts have greater commercial value than racemic acids andtheir salts, there is a growing interest in finding improved methods toselectively crystallize such salts from solutions containing the racemicacid and a chiral amine.

SUMMARY OF INVENTION

The inventive process includes selectively crystallizing a salt ofoptically active α-aryl carboxylic acid in more than 50% yields withrecycle and in high enantiomeric excess from a solution typicallycontaining the racemic form of the same acid and a suitable opticallyactive amino acid. Suitable amino acids include optically active lysine,arginine, histidine. The α-aryl carboxylic acid is of the formulaAr(R)CHCO₂ H, wherein R is selected from the group consisting of C₁ -C₈alkyl and C₁ -C₈ substituted alkyl, and Ar is selected from the groupconsisting of phenyl, substituted phenyl, 2-naphthyl, substituted2-naphthyl, 2-fluorenyl, and substituted 2-fluorenyl. The inventiveprocess includes (a) forming a solution of a mixture of enantiomers ofα-aryl carboxylic acid in a suitable solvent; (b) adding a suitableoptically active amino acid such that the amount of said amino acid isnot more than about a molar equivalent of the desired enantiomer in saidracemic acid; (c) optionally seeding the above mixture with purecrystals of the salt of said α-aryl carboxylic acid and said amino acidand letting it form crystals of the desired salt, typically at a certaintemperature range, e.g. about -10° C. to about +10° C. for a firstenantiomer and about +15° C. to about +25° C. for the second enantiomer,over a period of about 0.25 to about eight (8) hours for the firstenantiomer and about eight (8) hours to about 96 hours for the secondenantiomer; (d) separating the crystals of the desired salt enriched inone enantiomer of said acid; (e) substantially evaporating the solventto isolate the other enantiomer of the α-aryl carboxylic acid; (f)racemizing said other: enantiomer of step (e) to give racemic α-arylcarboxylic acid which is then recycled to step (a) of the next batch,thus ultimately converting all racemic α-aryl carboxylic acid intoalmost exclusively the salt of one enantiomer; and (g) optionallyacidifying the salt of step (f) to liberate free optically active α-arylcarboxylic acid.

In another facet of the present invention, there is provided a processwhich includes (a) forming a solution of a mixture of first and secondenantiomers of α-aryl carboxylic acid in a suitable solvent; (b) addinga suitable optically active amino acid such that the amount of saidamino acid is not more than about a molar equivalent of one enantiomer;(c) precipitating from said mixture at a first temperature a first saltof said optically active amino acid and said α-aryl carboxylic acidenriched in said first enantiomer; (d) increasing the temperature ofsaid mixture to a second temperature; (e) holding said (reaction)mixture containing said precipitated first salt for a sufficient periodof time at said temperature whereby said precipitated first saltredissolves into said (reaction) mixture and a second salt of saidoptically active amino acid and said α-aryl carboxylic acid enriched insaid second enantiomer precipitates; and (f) separating the precipitatedcrystals of said second salt from the reaction mixture.

The inventive process is described in detail below in connection withselective crystallization of the L-lysinate salt of S(+)-ibuprofen fromtypically racemic ibuprofen and L-lysine. [The term S-ibuprofen andS(+)-ibuprofen are hereinafter used interchangeably, as are the termsR-ibuprofen and R(-)-ibuprofen.] Although the instant invention isdescribed herein as a process for resolving racemic ibuprofen, it ispotentially useful to prepare optically active α-aryl carboxylic acidsin general whether or not the initial acid feed is racemic. It is to beunderstood that throughout the specification, "lysine hydrochloride"refers to the monohydrochloride salt of lysine, and "protonated cationof lysine" refers to the monocation of lysine. L-lysine, S-lysine,(+)-lysine, and d-lysine are different names for the same enantiomer;D-lysine, R-lysine, (-)-lysine, and 1-lysine are different names for theother enantiomer.

BRIEF DESCRIPTION OF DRAWINGS

The invention is described in detail below with reference to FIGS. 1-8which are flow diagrams of procedures of the present invention asdescribed in the examples which follow.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In one embodiment, the invention discloses a novel process toselectively crystallize salts of optically active ibuprofen fromsolutions containing racemic ibuprofen and an optically active aminoacid which forms the salt with the desired enantiomer of ibuprofen. Theprocess, unlike conventional resolution methods, yields, after recycleover several batches, the desired isomer in high yields with highenantiomeric excess, while using not more than about a molar equivalentof the amino acid based on the desired enantiomer of ibuprofen in anysingle batch. Furthermore, after removing the desired isomer salt fromthe mix, the undesired isomer of ibuprofen present in the mother liquorsis racemized, preferably without any added catalyst or solvent. Suchracemization is environmentally desirable, and permits direct recycle ofthe undesired enantiomer thus ultimately resulting in virtually completeconversion of racemic ibuprofen feed to the salt of the desiredenantiomer. The following description illustrates the isolation of thesalt of S-ibuprofen.

The process typically begins by forming the salt of racemic ibuprofenwith an optically active amino acid such as, for example, L-lysine. Thereaction is conducted in a solvent mixture of a suitable alcohol andwater. Suitable alcohols are those that can dissolve the ibuprofen andare also miscible with water. Examples include, but are not limited to,methanol, ethanol, n-propanol, isopropanol, 1-butanol, 2-butanol,isobutyl alcohol, t-butyl alcohol, 1-pentanol, 2-pentanol, 3-pentanol,2-methyl-l-butanol, 2-methyl-2-butanol, 3-methyl-2-butanol,3-methyl-1-butanol, neopentyl alcohol, and the like, with ethanol andmethanol being the preferred, and ethanol the most preferred. Generallythe ibuprofen is dissolved in the alcohol to which the requisite amountof an aqueous solution of the amino acid, L-lysine, is added. The amountof water in the total mix ranges generally from 1 part of water for 99parts of the alcohol to 10 parts of water for 90 parts of the alcohol,typically from 2 parts of water for 98 parts of the alcohol to 7 partsof water for 93 parts of alcohol, and preferably from 3 parts of waterfor 97 parts of the alcohol to 5 parts of water for 95 parts of thealcohol. The amount of the amino acid in the mixture is not more thanabout a molar equivalent of the S(+)-ibuprofen in the racemic acid,typically about 0.6 to 1.0 molar equivalent, and preferably about 0.7 to0.9 molar equivalent. The same ratios are preferable with respect toother α-aryl carboxylic acid/amino acid pairs. The concentration ofdissolved solids in the alcohol-water mixture ranges from about 3 toabout 30 weight percent.

The above mixture is then partially distilled with a suitableazeotroping agent to lower the water content of the mixture to about 0.5to 12.0 wt %. Suitable water-immiscible azeotroping agents and organicsolvents for this and other steps of the present process include, butare not limited to benzene, toluene, ethylbenzene, xylene,chlorobenzene, or other aromatics; methyl t-butyl, ethyl t-butyl, ethyln-butyl, di-n-propyl, diisopropyl, dibutyl, or other ethers; methyl,ethyl, isopropyl, butyl, propyl, isobutyl, t-butyl, or pentyl acetate,propionate, butyrate, isobutyrate, or valerate, or other esters; linear,cyclic, or branched penlanes, heptanes, hexanes, octanes, or nonanes;other C₄ to C₁₀ hydrocarbons, ethers, and esters; and the like, withcyclohexane, heptane and cycloheptane being the preferred, withcyclohexane and heptane being the most preferred. The mixture is thencooled to about -10° C. to about 10° C., preferably at about -10° C. toabout 5° C, and typically at about -5° C. to about 5° C., to startcrystallization of S(+)-ibuprofen lysinate salt. The mixture mayoptionally be seeded with pure crystals of S(+)-ibuprofen lysinate toinduce crystallization. Whether seeded or not, the solution ismaintained at the above-described temperature for a period of about 0.25to 8 hours. If seeding is desired, usually a small amount of seed, a fewcrystals, is sufficient. The separated first crop crystals of crudeS-ibuprofen L-lysinate may be separated by processes such as filtration,centrifugation and the like. This first crop is highly enriched,generally to more than 90%, in the S-form of ibuprofen.

The first crop crystals of crude S(+)-ibuprofen L-lysinate may berecrystallized as follows. The crystals are mixed with an alcohol-watermixture of the types described above, at about 40° to 80° C. generally,and about 50° to 78° C. preferably, to form about a 3 to 40 wt %mixture. This mixture is then cooled to about -10° C. to about 10° C.for about 0.25 to 8 hours to crystallize pure S(+)-ibuprofen L-lysinate.The mixture may be optionally seeded with the crystals of S(+)-ibuprofenL-lysinate to induce crystallization, if seeding is desired.Enantiomeric purities of more than 99% in the S(+) form of ibuprofen maybe obtained.

Alternatively, the recrystallization may be carded out in a solvent withhigher water content, e.g. 7% water and 93% ethanol to 20% water and 80%ethanol and preferably 10% water and 90% ethanol, to form themonohydrate of the S(+)-ibuprofen L-lysinate. The mixture may beoptionally seeded with crystals of S(+)-ibuprofen L-lysinate monohydrateto induce crystallization, if seeding is desired. Enantiomeric purifiesof more than 99% in the S(+) form of ibuprofen may be obtained.

The crude S(+)-ibuprofen lysinate from first crop crystallization isoptimally washed with 0° C. absolute ethanol. RecrystallizedS(+)-ibuprofen lysinate (as the monohydrate) can be washed with 0° C.98:2 ethanol:water without losing the water of hydration, and theresulting wash liquor can be used to wash the crude S(+)-ibuprofenlysinate from first crop crystallization.

The filtrates or mother liquor [stream 7] from the first cropcrystallization (Example 2) contain R-enriched ibuprofen free acid, andsmall amounts of lysine as the lysinate salt of ibuprofen. Most of thislysine may optionally be removed and recovered from this R(-)-enrichedibuprofen free acid by any of a number of procedures, eitherindividually or in combination, such as Examples 4, 5, 8, 9, 10, and 24below, (FIGS. 2-4 and 8) or as follows. The filtrates may beconcentrated azeotropically to reduce the water content of the filtratesto about 0.01 to 3 wt %. The concentrated filtrates may then be cooledto about 0° C. to 35° C. to deposit a second crop of ibuprofen lysinate.Alternately, a non-solvent such as, for example, hexane may be added tothe mixture to precipitate the second crop ibuprofen lysinate. Thissecond crop ibuprofen lysinate salt which has an S/R enantiomeric ratioof about 20:80 may then be recycled to the next batch's first cropcrystallization of crude S(+)-ibuprofen L-lysinate.

The mother liquors after removing the second crop ibuprofen lysinatesalt may be evaporated to leave behind a residue of substantiallylysine-free R-enriched ibuprofen which is racemized as described below,and then recycled to first crop crystallization of crude S(+)-ibuprofenlysinate.

Racemization of the R-enriched ibuprofen may be accomplished by severalmethods. For example, U.S. Pat. No. 5,015,764 referred to above,describes racemization in the presence of triethylamine in octane for 18hours, or in concentrated hydrochloric acid for 72 hours, or in:refluxing isopropanol in the presence of NaOH for 16 hours. U.S. Pat.No. 4,946,997 describes racemization in refluxing isopropyl acetate inthe presence of acetic anhydride and sodium acetate, or by heatingibuprofen acid chloride with sodium ibuprofenate. Ruchardt et al, Angew.Chem. Int. Ed. Engl., Vol. 23, page 162 (1964) discloses racemization byrefluxing in acetic anhydride and pyridine. While such methods can beused for racemization in the instant case, they, however, have severaldisadvantages. They generally consume reagents which produce by-productsnecessitating elaborate separation and waste disposal procedures. Theyalso are carried out in solvents requiring procedures for separation andrecovery. Some of the reagents and solvents are also toxic.

It has been found, as an aspect of the present invention, thatcompositions which consist essentially of an optically active α-arylcarboxylic acid, free from solvents, catalysts, and the like, can bespontaneously racemized by heating under an inert atmosphere. The inertatmosphere may be provided by nitrogen, argon, and the like. Thetemperature of heating is generally in the range 100° C. to 300° C.,typically about 100° C. to 250° C., and preferably about 200° C. to 250°C. The duration of heating is usually about one (1) to ten (10) hoursgenerally, two (2) to eight (8) hours typically, and three (3) to six(6) hours preferably. Such racemization can also be achieved by heatingin air to a temperature generally in the range 50° C. to 300° C.,typically about 80° C. to 280° C., and preferably about 100° C. to 250°C. The duration of heating is usually about one (1) to ten (10) hoursgenerally, two (2) to eight (8) hours typically, and three (3) to six(6) hours preferably. As used herein, the term "consisting essentiallyof" refers to a pure isomer or a mixture of isomers of the same α-arylcarboxylic acid, i.e. the R and S isomers, but specifically excludesother ingredients such as solvents, catalysts, and the like, that wouldalter the basic and novel characteristics of the invention. Theracemization conditions depend on the thermal properties of thematerial, such as, for example, thermal decomposition characteristics.Such properties may be ascertained by analytical techniques known tothose skilled in the art, such as thermal gravimetric analysis,differential scanning calorimetry, and the like. The goal is to findconditions where thermal decomposition of the material during heatingwould be minimal. The progress and completion of the racemization may beascertained by analytical techniques such as, for example, chiral HighPressure Liquid Chromatography (chiral HPLC). Heating R-ibuprofen orR-enriched ibuprofen under the above-described conditions effectivelyconverts half of the optically active acid to its mirror image, thusproducing the racemic modification as the product. Similar racemizationmay be performed on S-ibuprofen or S-enriched ibuprofen also.

Racemic ibuprofen obtained from the racemization reaction above may besubjected to selective crystallization as described above to isolatemore S-ibuprofen lysinate. Preferably, the racemic ibuprofen from theracemization reaction is vacuum distilled at about 150° C. to 250° C.The distillation residue, with recycles fully implemented, weighsgenerally about 2% of the final S-ibuprofen lysinate product weight. Thedistilled, racemized ibuprofen is recycled to the next batch's selectivecrystallization to isolate more S-ibuprofen lysinate. By combining theracemization and selective crystallization, the inventive processproduces S-ibuprofen L-lysinate in yields substantially more than 50%,generally close to 100%, based on the amount of racemic ibuprofen andlysine feeds.

The previously described removal and recovery of residual lysine fromthe R(-)-enriched ibuprofen free acid in the first crop crystallizationmother liquor [stream 7] is desirable, because most such lysineundergoes conversion to amides of lysine with or without ibuprofenduring racemization and distillation (Example 6). However, proceduresfor such removal and recovery of lysine are not essential and may bedeleted, because racemic ibuprofen is distilled off from lysine and itsamide decomposition products (Example 6), and the losses of lysine andibuprofen to the residue of such distillation would not be prohibitive.

Although the process has been described above for the L-lysinate salt ofS(+)-ibuprofen, substantially the same process can be used for selectivecrystallization of salts of other similar optically active α-arylcarboxylic acids using other similar optically active amino acids. Theα-aryl carboxylic acids include, but are not limited to, naproxen,fenoprofen, indoprofen, ketoprofen, flurbiprofen, pirprofen, suprofen,cicloprofen, minoxiprofen, carprofen, benoxaprofen, bisiprofenum,fluprofen, clidimac, tertiprofen, hexaprofen, mexoprofen, pranoprofen,and the like. The amino acids include arginine and histidine.

The S(+)-ibuprofen L-lysinate may optionally be acidified to yield thefree S(+)-ibuprofen. Suitable acids include acetic acid, carbonic acid,formic acid, propionic acid, C₄ to C₅ acids, hydrochloric acid, sulfuricacid, and the like. Suitable solvents include hexane, heptane,cyclohexane, xylene, and the other aforementioned solvents. The solventis preferably, but not necessarily, the same as the azeotroping agent.In a typical process, the salt is treated, in a two-phase mixture of anorganic solvent and water, with hydrochloric acid. L-Lysinehydrochloride forms and stays in the aqueous layer, while free acidS(+)-ibuprofen stays in the organic layer. The two layers are separatedand S(+)-ibuprofen may be isolated by removing the organic solvent.L-Lysine hydrochloride in the aqueous layer may be converted to L-lysinewhich may then be recycled in the selective crystallization process. Ifacetic acid is used in the process, L-lysine acetate forms in theprocess, which may be isolated from the aqueous layer and processed tofree L-lysine by lysine acetate cracking described below in theExamples.

The following examples are provided for purposes of illustration onlyand not by way of limitation. The various steps described in Examples1-14 are illustrated schematically in FIGS. 1 to 7.

EXAMPLE 1

Precipitation of NaCl from Aqueous Lysine. Referring to FIG. 1, amixture containing L-lysine hydrochloride (53.48 g, 0.2928 mole) andwater (53.48 g) [stream 2, FIG. 1] is added to a stirred mixturecontaining sodium hydroxide (11.71 g, 0.2928 mole) [from stream 3] andethanol (221.3 g) [from stream 24a] at 60° C. Heptane [stream 22a] andethanol [stream 24a are added to the resulting stirred mixture as anazeotrope [stream 21a] of water, ethanol, and heptane is removed bydistillation at atmospheric pressure until the weight ratio ofwater:ethanol:lysine is lowered to 7:93:17.988. The resulting mixture isfiltered hot to remove a solid [stream 4, 17.11 g] consisting mostly ofNaCl from a solution [stream 5a] containing free lysine.

EXAMPLE 2

First Crop Crystallization of S(+)-Ibuprofen Lysinate from RacemicIbuprofen in Aqueous Ethanol. To a stirred mixture containingS(+)-ibuprofen (0.538 moles, 110.98 g), R(-)-ibuprofen 0.597 moles,123.11 g), L-lysine (0.43023 moles, 62.895 g), ethanol (606 g), andwater (ca. 125 g) [from streams 5a, b; 6a; 8; 11; 19; 24b; and 26a, b,c; FIG. 1] is added heptane [from stream 22b] and ethanol [from stream24b] as an azeotrope [stream 21b] of water, ethanol, and heptane isremoved by distillation at atmospheric pressure until the weight ratioof water: ethanol: lysine is lowered to 6:94:9.747. The stirred,undistilled residue is cooled to 25° C. and seeded with S(+)-ibuprofenlysinate crystals (143 mg). The stirred mixture is seeded with twoadditional 143 mg portions of S(+)-ibuprofen lysinate crystals, oneafter the stirred mixture has been cooled further to 0° C. and the otherfifteen minutes later. After the mixture is stirred at 0° C. for 4hours, the resulting precipitate is filtered from the mother liquor[stream 7] and then washed with a mixture [stream 12] containing ethanol(138 g) and water (12 g). The washed precipitate [stream 9] is the firstcrop crude S(+)-ibuprofen lysinate (0.3442 mole, 121.32 g dry basis)with an ibuprofen S/R ratio of 94:6. The wash liquor [stream 8] isrecycled to the next batch's first crop crystallization ofS(+)-ibuprofen lysinate.

EXAMPLE 3

Recrystallization of S(+)-Ibuprofen Lysinate. First crop crudeS(+)-ibuprofen lysinate [stream 9, FIG. 1, 0.3442 mole, 121.32 g drybasis] is dissolved in a stirred mixture [stream 24c, FIG. 1] containingethanol (357 g) and water (31 g) at 70° C. The resulting stirred mixtureis cooled to 25° C., seeded with S(+)-ibuprofen lysinate monohydratecrystals (200 mg), and then cooled further to 0° C. for 4 hours. Theresulting precipitate is filtered from the mother liquor [stream 11 ]and then washed with a mixture [stream 24d] containing ethanol (138 g)and water (12 g). The washed precipitate [stream 10] is pureS(+)-ibuprofen lysinate monohydrate (0.2837 mole, 100 g dry basis) withan ibuprofen S/R ratio of>99.5:1. The wash liquor [stream 12] is used towash the next batch's crude S(+)-ibuprofen lysinate from first cropcrystallization.

EXAMPLE 4

Evaporation of Solvent from the Mother Liquor of First CropCrystallization. Water and ethanol are removed as azeotrope stream 21cby distillation in an evaporator from a mixture [stream 7; FIG. 1]containing S(+)-ibuprofen (0.2145 moles, 44.25 g), R(-)-ibuprofen(0.5763 moles, 118.89 g), L-lysine (0.08603 moles, 12.577 g), ethanol(ca. 570 g), and water (ca. 36.4 g). During the distillation, water [30g, stream 25a] is injected into the base of the evaporator to help stripout the last traces of ethanol and to prevent formation of amides andethyl esters. The molten evaporation residue [stream 13] containsS(+)-ibuprofen (0.2145 moles, 44.25 g), R(-)-ibuprofen (0.5763 moles,118.89 g), and L-lysine (0.08603 moles, 12.577 g).

EXAMPLE 5

Second Crop Crystallization of Ibuprofen Lysinate. A molten mixture[stream 13, FIG. 2] containing S(+)-ibuprofen (0.2145 moles, 44.25 g),R(-)-ibuprofen (0.5763 moles, 118.89 g), and L-lysine (0.08603 moles,12.577 g) is added to heptane [350 g, stream 14a] heated to 50° C. Theresulting mixture is stirred for 15 minutes and then filtered at 50° C.to remove precipitated ibuprofen lysinate from the mother liquor. Thefiltered solid is washed with heptane [50 g, stream 14b]. The mother andwash liquors are combined to provide a mixture [stream 15] containingS(+)-ibuprofen (0.1912 moles, 39.43 g) and R(-)-ibuprofen (0.5136 moles,105.95 g). The washed filtered solid is a second crop of ibuprofenlysinate and is dissolved in a mixture [stream 23a] containing water (15g), ethanol (76 g), and heptane (9 g). The resulting aqueous mixture[stream 16] contains ibuprofen lysinate (0.08603 moles, 30.32 g,ibuprofen S/R ratio of 27:73) and is recycled as stream 26a to the nextbatch's first crop crystallization of crude S(+)-ibuprofen lysinate.

EXAMPLE 6

Racemization and Distillation of R(-)-Enriched Ibuprofen. Heptane isremoved as stream 18, FIG. 1, by distillation in an evaporator atatmospheric pressure from a mixture [stream 15, FIG. 1] containingS(+)-ibuprofen (0.1912 moles, 39.43 g), R(-)-ibuprofen (0.5136 moles,105.95 g), and heptane (ca. 390 g). During the distillation, water [30g, stream 17] is injected into the base of the evaporator to help stripout the last traces of heptane and to minimize formation of ibuprofenethyl ester. The molten evaporation residue [stream 33], which consistsessentially of ibuprofen with an S/R ratio of 27/73, is first racemizedby being heated under nitrogen at 220° C. for four (4) hours and is thendistilled at about 220° C., 10 mm HgA in an evaporator to provide adistillate [stream 19] of substantially pure racemized ibuprofen (0.6907moles, 142.48 g, S/R ratio of 47:53) and an undistilled residue [stream20, 2.91 g] for incineration as a waste stream. Racemized ibuprofendistillate [stream 19] is recycled to the first crop crystallization ofcrude S(+)-ibuprofen lysinate.

Heptane/water distillate stream 18 is allowed to phase in a decanter toprovide a heptane upper phase [stream 14]and a water lower phase [stream17].

EXAMPLE 7

Separation of Azeotrope Streams. Azeotrope distillate streams 21a-d arecombined and allowed to separate into two liquid phases inside adecanter (FIG. 1). The alkane upper phase [stream 22] is a 94.8: 5.0:0.2 mixture by weight of heptane, ethanol, and water. The aqueous lowerphase [stream 23] is a 75.9: 15.0: 9.1 mixture by weight of ethanol,water, and heptane, a portion of which provides stream 23a. Theremainder of the aqueous lower phase [stream 23] is distilled to providea 92:8 by weight overhead mixture [stream 24] of ethanol and water and aheavy end [stream 25] of substantially pure water. A portion of heavyend water stream 25 is waste water stream 25c, which could be used as apure water feed for other processes.

EXAMPLE 8

Extraction of Ibuprofen Lysinate from the Crystallization Liquor'sEvaporation Residue with Water. This procedure is an alternative to theabove-described second crop crystallization of crude ibuprofen lysinate(Example 5). A molten mixture [stream 13, FIGS. 1, 3] containingS(+)-ibuprofen (0.2145 moles, 44.25 g), R(-)-ibuprofen (0.5763 moles,118.89 g) and L-lysine (0.08603 moles, 12.577 g) is injected into themiddle of a York-Scheibel-type counter-current extractor fed at the topwith a mixture [stream 23a] containing water (15 g), ethanol (76 g), andheptane (9 g) and at the bottom with a mixture [stream 22c] containingheptane (350 g), ethanol (18.5 g), and water (0.73 g). The aqueous lowerphase removed from the bottom of the extractor is a mixture [stream 16]containing ibuprofen lysinate (0.08603 moles, 30.32 g, ibuprofen S/Rratio of 27:73) and is recycled as stream 26b to the next batch's firstcrop crystallization of crude S(+)-ibuprofen lysinate. The alkane upperphase removed from the top of the extractor is a mixture [stream 15]containing S(+)-ibuprofen (0.1912 moles, 39.43 g) and R(-)-ibuprofen(0.5136 moles, 105.95 g) and is evaporated and racemized as described inExample 6, except that the evaporated solvent is recycled as azeotropestream 21 d and not as stream 18.

EXAMPLE 9

Extraction of Ibuprofen Lysinate from the Crystallization Liquor'sEvaporation Residue with Aqueous HCl. This procedure is an alternativeto the above-described second crop crystallization of crude ibuprofenlysinate (Example 5). A molten mixture [stream 13, FIGS. 1, 4]containing S(+)-ibuprofen (0.2145 moles, 44.25 g), R(-)-ibuprofen(0.5763 moles, 118.89 g) and L-lysine (0.08603 moles, 12.577 g) is addedto a 50° C. mixture containing heptane (400 g), water (16 g), and HCl(0.08603 mole, 3.137 g) [from streams 14 and 27a]. The resulting mixtureis mixed thoroughly and then allowed to phase. The upper phase is amixture [stream 15] containing ibuprofen (0.7908 moles, 163.13 g; S/Rratio of 27:73) and heptane (ca. 400g). The lower phase is an aqueousmixture [stream 28a] containing lysine hydrochloride (0.08603 moles,15.71 g) and is recycled as stream 36a to precipitation of NaCl fromaqueous lysine (Example 1 ), or to ion exchange (Example 22) orelectrodialysis (Example 23).

EXAMPLE 10

Extraction of Ibuprofen Lysinate from the Crystallization Liquor'sEvaporation Residue with Aqueous Acetic Acid. This procedure is analternative to the above-described second crop crystallization of crudeibuprofen lysinate (Example 5). A molten mixture [stream 13, FIG. 4]containing S(+)-ibuprofen (0.2145 moles, 44.25 g), R(-)-ibuprofen(0.5763 moles, 118.89 g) and L-lysine (0.08603 moles, 12.577 g) is addedto a 50° C. mixture containing heptane (400 g), water (167. g), andacetic acid (0.08603 mole, 5.166 g) [from streams 14 and 27a]. Theresulting mixture is mixed thoroughly and then allowed to phase. Theupper phase is a mixture [stream 15] containing ibuprofen (0.7908 moles,163.13 g; S/R ratio of 27:73) and heptane (ca. 400 g). The lower phaseis an aqueous mixture [stream 28a] containing lysine acetate (0.08603moles, 17.743 g) and is recycled as stream 32a to lysine acetatecracking (Example 13 or 14).

EXAMPLE 11

Conversion of S(+)-Ibuprofen Lysinate to S(+)-Ibuprofen Free Acid byTreatment with HCl. A mixture of S(+)-ibuprofen lysinate (0.2837 mole,100 g dry basis), heptane (88 g), S(+)-ibuprofen (8.53 mmole, 1.76 g),water (52 g), and HCl (0.2837 mole, 10.344 g) [from streams 10, 27b, and29, FIG. 5] is mixed thoroughly at 60° C. and then allowed to phase. Thelower phase is an aqueous mixture [stream 28b] containing lysinehydrochloride (0.2837 moles, 51.82 g) and is recycled as stream 36b toprecipitation of NaCl from aqueous lysine (Example 1 ), to ion exchange(Example 22), or to electrodialysis (Example 23). The upper phase[stream 30] is a mixture containing S(+)-ibuprofen free acid (0.29223moles, 60.283 g) and heptane (ca. 88 g) and is cooled from 60° C. to 0°C. to crystallize S(+)-ibuprofen free acid. The S(+)-ibuprofen free acid[stream 31, 0.2837 mole, 58.52 g] is removed by filtration from theheptane mother liquor [stream 29], which contains S(+)-ibuprofen (8.53mmole, 1.76 g).

EXAMPLE 12

Conversion of S(+)-Ibuprofen Lysinate to S(+)-Ibuprofen Free Acid byTreatment with Acetic Acid. A mixture of S(+)-ibuprofen lysinate (0.2837mole, 100 g dry basis), heptane (88 g), S(+)-ibuprofen (8.53 mmole, 1.76g), water (551 g), and acetic acid (0.2837 mole, 17.037 g) [from streams10, 27b, and 29, FIGS. 1,5] is mixed thoroughly at 60° C. and thenallowed to phase. The lower phase is an aqueous mixture [stream 28b]containing lysine acetate (0.2837 moles, 58.51 g) and is recycled asstream 32b to lysine acetate cracking (Example 13 or 14). The upperphase [stream 30] is a mixture containing S(+)-ibuprofen free acid(0.29223 moles, 60.283 g) and heptane (ca. 88 g) and is cooled from 60°C. to 0° C. to crystallize S(+)-ibuprofen free acid. The S(+)-ibuprofenfree acid [stream 31, 0.2837 mole, 58.52 g] is removed by filtrationfrom the heptane mother liquor [stream 29], which containsS(+)-ibuprofen (8.53 mmole, 1.76 g).

EXAMPLE 13

Lysine Acetate Cracking. To a stirred mixture [streams 32 a,b, FIG. 6]containing lysine acetate (0.36973 moles, 76.254 g) and water (718 g) isadded water [stream 25b, 54 g] and heptane [from stream 34] as anazeotrope [stream 35] of water, acetic acid, and heptane is removed bydistillation at atmospheric pressure. The distillation residue [stream5b] contains free lysine (0.36973 moles, 54.05 g) and water (54 g) forrecycle to first crop crystallization (Example 2). Distillate stream 35is allowed to phase in a decanter to provide a heptane upper phase[stream 34] and an aqueous acid lower phase [stream 27] containingacetic acid (0.36973 moles, 22.202 g) and water (718 g).

EXAMPLE 14

Lysine Acetate Cracking with Ibuprofen. To a stirred mixture containingracemic ibuprofen (0.36973 moles, 76.27 g), lysine acetate (0.36973moles, 76.254 g) and water (718 g) [from streams 6b and 32a, b, FIG. 7]is added water [stream 25b, 150 g] and heptane [from stream 34] as anazeotrope [stream 35] of water, acetic acid, and heptane is removed bydistillation at atmospheric pressure. The distillation residue [stream26c] contains ibuprofen lysinate (0.36973 moles, 130.32 g) and water(150 g) for recycle to first crop crystallization (Example 2).Distillate stream 35 is allowed to phase in a decanter to provide aheptane upper phase [stream 34] and an aqueous acid lower phase [stream27] containing acetic acid (0.36973 moles, 22.202 g) and water (718 g).

The following examples (15-21) and the subsequent discussion describethe other facet of this invention wherein there is provided a simple,unprecedented and highly efficient diastereoselective crystallization ofeither enantiomer of ibuprofen as its L-lysinate salt from a mixture ofracemic ibuprofen and the same commercially available inexpensiveresolving agent, L-lysine. The process obviates the shortcomingsassociated with both classical resolution (involving expensive syntheticresolving agents) and enzyme technology. The process also produces theenantiomerically enriched ibuprofen directly as the preferred lysinatesalt which is desirable for human consumption, thereby avoiding theobligatory separation of ibuprofen (free enantiomer) from a chiralauxiliary. As chemical resolution technology continues to play adominant role (despite increasing competition from the enzymaticmethods), the potential offered by such selective crystallizationtechnology is substantial.

EXAMPLE 15

Preparation of Free Aqueous L-Lysine from L-Lysine Hydrochloride. Achromatography column was packed with 68.6 gM of Amberlyte IRA-400 (OH)ion exchange resin (capacity 1.6 m eq./gM). The resin was washed with 25mL water. A solution of L-lysine monohydrochloride (18.2 gM) dissolvedin 35 mL of water was added to the top of the column. The column waseluted with 200 mL water and the combined aqueous fractions wereconcentrated in the rotovapor to total dryness, producing 13.31 g (92%yield) of L-lysine which was used in the selective crystallizationprocess without further purification.

EXAMPLE 16

Selective Crystallization of S-Ibuprofen L-Lysinate Utilizing L-Lysine.Racemic (RS)-ibuprofen (41.25 g, 0.20 mol) was dissolved in ethanol (140mL). The solution was cooled to 0° C. L-lysine (11.7 g, 0.080 Moldissolved in 7 mL water) was added to this solution via addition funnelwhile the solution temperature was maintained at 0° C. The solution wasseeded with S-ibuprofen L-lysinate (0.1 g). The resulting mixture wasstirred at 0° C. for four (4) hours. The crystals were filtered, washedwith ice-cold (2° C.) ethanol (40 mL) and dried under vacuum overnightto produce 19.64 g (70% yield based on L-lysine) of S-ibuprofenL-lysinate salt in 94% diastereomeric purity as evidenced by chiralHPLC.

EXAMPLE 17

Recrystallization to Produce Diastereomerically Pure S-IbuprofenL-Lysinate. 2g of S-ibuprofen L-lysinate (94% diastereomeric purity;obtained from Example 16) was dissolved in a mixture of ethanol (12 mL)and water (1.2 mL) at 60° C. The mixture was slowly cooled from 60° C.to 0° C. over a period of two (2) hours and stirred at 0° C. for two (2)hours. The crystals were filtered, washed with cold (0° C.) ethanol (6ml) and dried under vacuum overnight to produce 1.8 g (95% yield of theavailable S-salt) of the S-ibuprofen L-lysinate in>99% diastereomericpurity. (The slow gradual temperature gradient during the coolingprocess is essential to obtain the required diastereomeric purity. Thus,when the crystallization mixture was cooled at a faster rate (ca. 20minutes) the diastereomeric purity of the product was only 97%).

EXAMPLE 18

Selective Crystallization of R-Ibuprofen L-Lysinate. Racemic(RS)-ibuprofen (41.25 g, 0.20 Mol) was dissolved in ethanol (140 mL).The solution was cooled to 12° C. L-lysine (11.7 g, 0.080 Mol dissolvedin 7 mL water) was added to this solution via addition funnel while thesolution temperature was maintained at 12° C. The resulting mixture wasstirred at 22° C. for 48 hours. The crystals were filtered, washed withethanol (40 mL) and dried under vacuum overnight to produce 19.6 g (70%yield based on L-lysine) of R-ibuprofen L-lysinate salt in 98%diastereomeric purity as evidenced by chiral HPLC. The salt wasrecrystallized from ethanol/water as described in Example 17 to produce17.3 g (89% yield of the available R-salt) of the R-ibuprofen L-lysinatein >99% diastereomeric purity.

EXAMPLE 19

Preparation of S-Ibuprofen from S-Ibuprofen Lysinate. 35.2 g ofS-ibuprofen/lysinate (99% d.e.) was dissolved in 300 mL water at 22° C.The pH of the resulting solution was adjusted to one (1) via addition ofconcentrated aq. HCl. The mixture was stirred for one (1) hour at 22° C.The heterogeneous mixture was filtered. The crystals were dried at 50°C. under vacuum to produce 20.6 g. of S(+) ibuprofen (100% yield) of 99%enantiomeric excess as evidenced by chiral HPLC. The mother liquorcontaining L-lysine hydrochloride was recycled to the ion exchangelysine recovery process described in Example 15.

EXAMPLE 20

Preparation of R-Ibuprofen from R-Ibuprofen Lysinate. 35.2 g ofR-ibuprofen/lysinate (99% d.e.) was subjected to the same process asdescribed in Example 19 to produce 20.6 g of R-ibuprofen (100% yield) in99% enantiomeric purity as evidenced by chiral HPLC.

EXAMPLE 21

Selective Crystallization of R-Ibuprofen L-Lysinate. Racemic(RS)-ibuprofen (41.25 g, 0.20 Mol) was dissolved in ethanol (140 mL).The solution was held at 22° C. while L-lysine (11.7 g, 0.080 Moldissolved in 7 mL water) was added by addition funnel. The resultingmixture was seeded with R-ibuprofen L-lysinate crystals and then stirredat 22° C. for 48 hours. The precipitated crystals were filtered, washedwith ethanol (40 mL) and dried under vacuum overnight to produce 19.1 g(68% yield based on L-lysine) of R-ibuprofen L-lysinate salt in 98%diastereomeric purity as evidenced by chiral HPLC. The salt wasrecrystallized from ethanol/water as described in Example 17 to produce17.4 g (92% yield of the available R-salt) of the R-ibuprofen L-lysinatein >99% diastereomeric purity.

DISCUSSION OF EXAMPLES 16-21

As previously mentioned, RS-ibuprofen belongs to a class ofnon-steroidal anti-inflammatory agents that has remained an area ofintense study. S(+)-ibuprofen is the pharmacologically active componentof RS-ibuprofen. The R(-) isomer is either inactive or weakly active invitro although the difference in activity is markedly decreased in vitrodue to metabolic inversion of the R(-) to the active S(+) enantiomer. Onthe other hand, R(-)-ibuprofen, the therapeutically inactive isomer, isexpected to give less gastrointestinal side effects than the racemate,while still retaining its anti-inflammatory activity via metabolicinversion to the active S(+)-isomer. In order to realize enhancedspecificity, avert undesirable load on metabolism, and minimizegastrointestinal side effects, it is desirable to market S(+) ibuprofenin the form of its lysinate salt.

In light of such continuing interest in the area of S(+) ibuprofen,coupled with the recent demand for enantiomerically pure drugs inchemotherapy, an efficient preferential resolution of racemic (RS)ibuprofen is highly desirable. The existing methods for resolvingRS-ibuprofen via fractional crystallization of diastereomeric salts withchiral amine (e.g. α-methylbenzylamine, L-lysine) suffer from thefollowing disadvantages: (1) the maximum theoretical yield is only 50%(based on the chiral auxiliary), thus requiring additional steps forefficiently recovering and recycling the resolving agent, as well as theunwanted enantiomer; (2) although synthetic resolving agents (e.g.α-methylbenzylamine) are available in both enantiomeric forms, naturallyoccurring agents (e.g. L-lysine) are often only available in one (1)enantiomeric form, thereby limiting the scope of such diastereomericseparations.

This facet of the present invention describes an unprecedented selectivecrystallization of ibuprofen lysinate from one (1) mole of racemicibuprofen and ≦0.5 mole of L-lysine which enables the preparation ofeither enantiomer of ibuprofen (as well as the preferred lysinate salt)utilizing the inexpensive, naturally occurring and readily availableS-lysine as the chiral resolving agent and appropriate choice ofresolution conditions. The cost of naturally occurring L-lysine(available as the hydrochloride salt from Archer Daniel Midland Companyin 98.5% chemical purity and 100% optical purity) is $2.00/Kg., whereasthe enantiomeric D-lysine, which is required for the production ofR-(-)-ibuprofen via traditional classical resolution, currently costs$8000.00/Kg.

It has been unexpectedly found that in the selective crystallization ofS-ibuprofen/L-lysinate salt with not more than one (1) mole of L-lysineper mole of S-ibuprofen in the crystallization medium, the S-ibuprofenL-lysinate salt diastereomer crystallizes much more rapidly than doesthe R-ibuprofen L-lysinate salt diastereomer, thereby leaving the motherliquor enriched in R-ibuprofen as shown in Scheme 1 below. ##STR2##

Crystallization studies were conducted (as shown in Examples 15-20) byadding an aqueous solution of L-lysine to an ethanolic solution ofRS-ibuprofen followed by seeding. The diastereomeric excesses (d.e.) ofthe crystals (sampled at one (1) hour time intervals) were monitored bychiral HPLC analysis. Optimization with respect to temperature (0° C.),time (4 to 6 hours), lysine:S(+)-ibuprofen mole ratio (0.8:1), ethanolvolume (3.8 mL per gram combined weight of both ibuprofen enantiomers)and water concentration (5 wt. % with respect to ethanol) afforded a 70%isolated yield (based on available lysine) of S-ibuprofen lysinate in94:6 diastereomer ratio (88% diastereomeric excess (d.e.)). The productof the first crystallization can be recrystallized once from aqueousethanol (90 wt %) to afford ibuprofen lysinate monohydrate in 99% d.e.Maintaining the water content at about 10 wt % in the aqueous ethanolduring the recrystallization is imperative to obtain the requiredmonohydrate form in a reproducible manner.

Particularly noteworthy and remarkable in this invention is the factthat a complete reversal of diastereoselectivity was observed when thecrystallization was conducted at 22° C. for 48 hours under otherwiseidentical conditions, thereby producing the R-ibuprofen/L-lysinate in99:1 diastereomer ratio (98% d.e.). The same diastereoreversal was alsoobserved when the heterogeneous crystallization mixture obtained afterfour (4) hours at 0° C. (where the isolated crystals werediastereomerically enriched in S-ibuprofen/L-lysinate) was allowed tostir at ambient temperature (22° C.) for an additional 48 hours asdepicted in Scheme 2. Selective precipitation of theR-ibuprofen/L-lysinate would allow direct recovery of S(+)-ibuprofen asthe free acid from the mother liquor. ##STR3##

The following examples 22-27 illustrate another facet of the presentinvention and disclose recovery of the free aqueous lysine with carbondioxide and the purification of various by-product/recycle streams andthe separation of various materials from each other. Reference is alsomade to FIG. 8 for Examples 24-27.

EXAMPLE 22

Free Aqueous Lysine from Ion Exchange. A solution of L-lysinehydrochloride (0.36973 mole, 67.532 g) in water (68 g) [from stream 36ain Example 9 and stream 36b in Example 11] is added to the top of acolumn of Amberlyte IRA-400(OH) ion exchange resin (254.54 g, 0.4073equivalents) pre-washed with water. The column is subsequently elutedwith water (742 g) to provide an aqueous solution of free L-lysine fromwhich water is partially evaporated at 60° C. and 20 mm HgA pressure.The resulting evaporation residue [stream 5a] contains free L-lysine(0.36973 moles, 54.05 g) and water (54 g) for recycle to first cropcrystallization (Example 2).

The ion exchange column is regenerated by reverse elution with asolution of sodium hydroxide (0.4067 mole, 16.27 g) in water (68 g) toproduce a solution of sodium chloride (0.36973 mole, 21.608 g) in water(68 g) [stream 4]. The ion exchange column is then eluted with water toremove residual sodium hydroxide prior to addition of the next batch oflysine hydrochloride.

EXAMPLE 23

Generation of Free Aqueous Lysine by Electrodialysis with PermselectiveMembranes. A solution of L-lysine hydrochloride (0.36973 mole, 67.532 g)in water (68 g) [from stream 36a in Example 9 and stream 36b in Example11] is subjected to electrodialysis with permselective membranesaccording to the procedure described in example 9 of U.S. Pat. No.3,330,749, the entire contents of which are incorporated herein byreference. The resulting aqueous solution of free L-lysine incompartment A is partially evaporated at 60° C. and 20 mm HgA pressureto provide an evaporation residue [stream 5a] containing free L-lysine(0.36973 moles, 54.05 g) and water (54 g) for recycle to first cropcrystallization (Example 2). The aqueous solution of hydrochloric acid(0.36973 moles) in-compartment C is stream 4.

EXAMPLE 24

Extraction of Ibuprofen Lysinate from the Crystallization Liquor'sEvaporation Residue with Aqueous Carbonic Acid. This procedure is analternative to the procedures described in Examples 5, 8, 9, and 10above. A molten mixture [stream 13, FIGS. 1 and 8] containingS(+)-ibuprofen (0.2145 moles, 44.25 g), R(-)-ibuprofen (0.5763 moles,118.89 g), and L-lysine (0.08603 moles, 12.577 g) is added to a mixturecontaining heptane (400 g) and water (30.32 g) [from streams 14, 25b,and 27a]. The resulting mixture is mixed thoroughly at 40° C. under 1000psi partial pressure of carbon dioxide and then allowed to phase. Thelower phase is separated from the upper phase under 1000 psi carbondioxide pressure. The upper phase is a mixture [stream 15] containingibuprofen (0.7908 moles, 163.13 g; S/R ratio of 27.73) and heptane (ca.400g). The lower phase is an aqueous mixture [stream 28a] containinglysine (0.08603 moles, presumably as bicarbonate, carbonate, and/orcarbamate salts) and water (30.32 g) and is then recycled tocarbonate/carbamate cracking of Examples 26 or 27.

EXAMPLE 25

Conversion of S(+)-Ibuprofen Lysinate to S(+)-Ibuprofen Free Acid byTreatment with Aqueous Carbonic Acid. This procedure is an alternativeto the procedures described in Examples 11 and 12 above. A mixture ofS(+)-ibuprofen lysinate (0.2837 mole, 100 g dry basis), heptane (155 g),S(+)-ibuprofen (8.53 mmole, 1.760 g), and water (100 g) [from streams10, 25b, 27b, 29, and 36; FIGS. 1 and 8] is mixed thoroughly at 40° C.under 1000 psi partial pressure of carbon dioxide and then allowed tophase. The lower phase is separated from the upper phase under 1000 psicarbon dioxide pressure. The lower phase is an aqueous mixture [stream28b] containing lysine (0.2837 moles, presumably as bicarbonate,carbonate, and/or carbamate salts) and water (100 g) and is recycled tocarbonate/carbamate cracking Example 26 or 27.

The upper phase [stream 30] is a mixture containing S(+)-ibuprofen freeacid (0.29223 moles, 60.283 g) and heptane (ca. 155 g). Heptane [stream36, 68 g] is removed from the upper phase by distillation at atmosphericpressure. The concentrated upper phase is then cooled to 0° C. tocrystallize S(+)-ibuprofen free acid. The crystalline S(+)-ibuprofenfree acid [stream 31, 0.2837 mole, 58.524 g] is removed by filtrationfrom the heptane mother liquor [stream 29], which containsS(+)-ibuprofen (8.53 mmole, 1.760 g) and heptane (87 g).

EXAMPLE 26

Lysine Carbamate/Carbonate Cracking. This procedure is used incombination with examples 24 and/or 25 above and is an alternative tothe procedures described in Examples 13 and 14 above. From a stirredmixture [streams 28a and 28b, FIG. 8] containing lysine (0.36973 moles,presumably as bicarbonate, carbonate, and/or carbamate salts) and water(130.32 g) is removed a water distillate [streams 27a and 27b, 76.32 gtotal] by distillation at atmospheric pressure. During thisdistillation, the salts of lysine are converted to free aqueous lysineand carbon dioxide, and carbon dioxide is removed with water by thedistillation. The distillation residue [stream 16] contains free lysine(0.36973 moles, 54.05 g) and water (54 g) for recycle [as stream 5b] tofirst crop crystallization (Example 2).

EXAMPLE 27

Lysine Carbamate/Carbonate Cracking with Ibuprofen. This procedure isused in combination with Examples 24 and/or 25 above and is analternative to the procedures described in Examples 13, 14, and 26above. Substantially racemic ibuprofen (0.36973 moles) is added to astirred mixture [streams 28a and 28b, FIG. 8] containing lysine (0.36973moles, presumably as bicarbonate, carbonate, and/or carbamate salts) andwater (130.32 g) at about 40° C. As the ibuprofen dissolves,bicarbonate, carbonate, and/or carbamate salts of lysine are convened toaqueous ibuprofen lysinate and carbon dioxide, the later of which isswept out of the reaction mixture with nitrogen gas. After substantiallycomplete removal of carbon dioxide, the reaction mixture [stream 16]contains ibuprofen lysinate salt (0.36973 moles, 130.322 g) and water(130.32 g) for recycle [as stream 26c] to first crop crystallization(Example 2).

Although the free L-lysine feed [stream 5a] to the first cropcrystallization (Example 2) may be purchased commercially (AldrichChemical Co.), L-lysine salts (such as the hydrogen sulfate andparticularly the hydrogen chloride salts) are much cheaper than freelysine and can be convened to free aqueous lysine by proceduresdescribed in Examples 1, 22, and 23. Furthermore, the present inventiondoes not require total removal of the negative counterion (e.g.,chloride, in Examples 1, 22, and 23) of the protonated L-lysine cationfeed (e.g., L-lysine hydrochloride in Examples 1, 22, and 23) from whichthe free aqueous L-lysine is generated. When the free aqueous L-lysine(e.g., stream 5a from Examples 1, 22, or 23) contains a portion of thisnegative counterion as an impurity, much of that impurity remains withthe first crop crystallization's mother and wash liquors (streams 7 and8, respectively, from Example 2), thereby avoiding or alleviatingcontamination of the crude S(+)-ibuprofen lysinate (stream 9 fromExample 2). This negative counterion impurity can be purged from theprocess in stream 4 by processing and recycle of streams 7 and 8 toExamples 1, 22, or 23 as described in Examples 4, 9, and 11. Otherimpurities in the free aqueous L-lysine feed [stream 5a] to first cropcrystallization might also be separated from desired product and purgedfrom the process in a similar fashion.

Thus, in one embodiment of the present invention, there is provided aprocess to selectively crystallize a salt of an optically active aminoacid and optically active ibuprofen, said process comprising, (1)providing a reaction mixture containing first and second enantiomers ofibuprofen, a solvent mixture, and a molar quantity of said amino acidsuch that the molar quantity of said amino acid is no greater than aboutthe molar quantity of one of said enantiomers of said ibuprofen; (2)precipitating from said mixture at a temperature below about 5° C.; asalt enriched in one enantiomer of ibuprofen; said amino acid isselected from the group consisting of lysine, arginine, and histidine.

In another embodiment of the present invention, there is an additionalstep to the process as follows: (3) holding the reaction mixturecontaining said precipitated salt for a sufficient period of time and ata temperature above about 5° C. whereby said precipitated saltredissolves into said reaction mixture and the other enantiomer of saidibuprofen precipitates out as a salt. In either of the aboveembodiments, the amino acid can be lysine.

Advantages of the present process for production of S(+)-ibuprofenlysinate salt from free L-lysine include the following. Use of L-lysinein a molar quantity no greater than the molar quantity of the S(+)enantiomer of the ibuprofen feed obviates any and all consumption ofother chemicals as well as any and all processing steps involving otherchemicals (except solvents). Another advantage of the present process isthat its only two waste streams are (1) substantially pure water [stream25c] in a quantity equal to the water content of fresh lysine feed and(2) a small amount (about 2% by weight of the final ibuprofen lysinateproduct), of a completely combustible organic residue [stream 20] fromdistillation of racemized ibuprofen. These advantages are consequencesof the fact that most of the R(-)-ibuprofen [stream 15] is neverconvened to an amine salt before racemization and recycle, therebypermitting (Example 5 or 8) the rest of the R(-)-ibuprofen [in stream26a or 26b, respectively] to be recycled as lysinate salt withoutracemization. Another advantage is that the ibuprofen S/R enantiomerratio is high (92:8 to 98:2) in the first crop of crude S(+)-ibuprofenlysinate salt and is readily increased to >200 by a singlerecrystallization of the crude salt. Another advantage is that efficientracemization of R-enriched ibuprofen is achieved thermally without useof any chemicals, solvents, or chemical treatment. No prior art processhas all of these advantages.

In another preferred embodiment of the present invention, there isprovided a process for preparing a first salt of an amino acid and anα-arylcarboxylic acid of the formula Ar(R)CHCO₂ H, from a second salt ofan anion and a protonated cation of said amino acid, said processcomprising: combining water, a base, and said protonated cation of saidamino acid to produce an aqueous solution of said amino acid; separatingsaid aqueous solution of said amino acid from a first portion of saidanion; precipitating said first salt of said amino acid and saidα-arylcarboxylic acid from a mixture incorporating said aqueous solutionof said amino acid, and separating said first salt from a second portionof said anion; wherein R is selected from the group consisting of C₁ -C₈alkyl and C₁ -C₈ substituted alkyl; Ar is selected from the groupconsisting of phenyl, substituted phenyl, 2-naphthyl, substituted2-naphthyl, 2-fluorenyl, and substituted 2-fluorenyl; and said aminoacid is selected from the group consisting of lysine, arginine, andhistidine.

In the above process, the anion can be chloride and the base can be ahydroxide ion or an ion exchange resin. Also, the aqueous solution ofsaid amino acid can be separated from said first portion of said anionwith a permselective membrane.

In still another preferred embodiment of the present invention, there isprovided a process for preparing a first salt of an amino acid and anα-arylcarboxylic acid of the formula Ar(R)CHCO₂ H, from a second salt ofan anion and a protonated cation of said amino acid, said processcomprising: combining water, a base, and said protonated cation of saidamino acid to produce an aqueous solution of said amino acid; separatingsaid aqueous solution of said amino acid from at least a portion of saidanion; combining said α-arylcarboxylic acid with said aqueous solutionof said amino acid to produce a mixture containing said first salt ofsaid amino acid and said α-arylcarboxylic acid; and combining said basewith at least one component of said mixture to at least partiallyregenerate said aqueous solution of said amino acid; wherein R isselected from the group consisting of C₁ -C₈ alkyl and C₁ -C₈substituted alkyl; Ar is selected from the group consisting of phenyl,substituted phenyl, 2-naphthyl, substituted 2-naphthyl, 2-fluorenyl, andsubstituted 2-fluorenyl; and said amino acid is selected from the groupconsisting of lysine, arginine, and histidine.

In this process said component can contain said anion or said protonatedcation of said amino acid. The base can be a hydrogen ion or an ionexchange resin. In this process, the aqueous solution of said amino acidcan be separated from said portion of said anion with an ion exchangeresin or with a permselective membrane. Furthermore, a portion of saidanion can be separated as a solid salt from said aqueous solution ofsaid amino acid. In this process, there can be further steps ofisolating said first salt from said mixture, combining said first saltwith a third acid, other than said amino acid and said α-aryl carboxylicacid, to produce said α-arylcarboxylic acid in an enantiomericallyenriched form and said protonated cation of said amino acid, andseparating said enantiomerically enriched α-arylcarboxylic acid fromsaid protonated cation of said amino acid, wherein said component issaid protonated cation of said amino acid.

In another preferred embodiment of the present invention, there isprovided a process for preparing a salt of an amino acid and anα-arylcarboxylic acid Ar(R)CHCO₂ H, said process comprising: distillingwater from a mixture containing said amino acid and saidα-arylcarboxylic acid and then precipitating said salt from saidmixture, wherein R is selected from the group consisting of C₁ -C₈ alkyland C₁ -C₈ substituted alkyl; Ar is selected from the group consistingof phenyl, substituted phenyl, 2-naphthyl, substituted 2-naphthyl,2-fluorenyl, and substituted 2-fluorenyl; and said amino acid isselected from the group consisting of lysine, arginine, and histidine.In this process, a water-immiscible azeotroping agent can be added tosaid mixture to assist said distillation, and the distillation producesa distillate containing two (2) liquid phases which are allowed toseparate and are then recycled independently.

What is claimed is:
 1. A process for preparing a first salt of an aminoacid and an α-arylcarboxylic acid of the formula: Ar(R)CHCO₂ H, from asecond salt of an anion and a protonated cation of said amino acid, saidprocess comprising: combining water, a base, and said protonated cationof said amino acid to produce an aqueous solution of said amino acid;separating said aqueous solution of said amino acid from a first portionof said anion; precipitating said first salt of said amino acid and saidα-arylcarboxylic acid from a mixture incorporating said aqueous solutionof said amino acid, and separating said first salt from a second portionof said anion, wherein R is selected from the group consisting of C₁ -C₈alkyl and C₁ -C₈ substituted alkyl; Ar is selected from the groupconsisting of phenyl, substituted phenyl, 2-naphthyl, substituted2-naphthyl, 2-fluorenyl, and substituted 2-fluorenyl; and said aminoacid is selected from the group consisting of lysine, arginine, andhistidine.
 2. The process of claim 1 wherein said anion is chloride. 3.The process of claim 2 wherein said base is a hydroxide ion.
 4. Theprocess of claim 1 wherein said base is an ion exchange resin.
 5. Theprocess of claim 1 wherein said aqueous solution of said amino acid isseparated from said first portion of said anion with a permselectivemembrane.
 6. A process for preparing a first salt of an amino acid andan α-arylcarboxylic acid of the formula Ar(R)CHCO₂ H, from a second saltof an anion and a protonated cation of said amino acid, said processcomprising: combining water, a base, and said protonated cation of saidamino acid to produce an aqueous solution of said amino acid; separatingsaid aqueous solution of said amino acid from at least a portion of saidanion; combining said α-arylcarboxylic acid with said aqueous solutionof said amino acid to produce a mixture containing said first salt ofsaid amino acid and said α-arylcarboxylic acid; combining said base withat least one component of said mixture to at least partially regeneratesaid aqueous solution of said amino acid, wherein R is selected from thegroup consisting of C₁ -C₈ alkyl and C₁ -C₈ substituted alkyl; Ar isselected from the group consisting of phenyl, substituted phenyl,2-naphthyl, substituted 2-naphthyl, 2-fluorenyl, and substituted2-fluorenyl; and said amino acid is selected from the group consistingof lysine, arginine, and histidine.
 7. The process of claim 6 whereinsaid component contains said anion.
 8. The process of claim 6 whereinsaid component contains said protonated cation of said amino acid. 9.The process of claim 6 wherein said base is a hydroxide ion.
 10. Theprocess of claim 6 wherein said base is an ion exchange resin.
 11. Theprocess of claim 6 wherein said aqueous solution of said amino acid isseparated from said portion of said anion with an ion exchange resin.12. The process of claim 6 wherein said aqueous solution of said aminoacid is separated from said portion of said anion with a permselectivemembrane.
 13. The process of claim 6 wherein said portion of said anionis separated as a solid salt from said aqueous solution of said aminoacid.
 14. The process of claim 6 further comprising isolating said firstsalt from said mixture, combining said first salt with a third acid,other than said amino acid and said α-arylcarboxylic acid, to producesaid α-arylcarboxylic acid in an enantiomerically enriched form and saidprotonated cation of said amino acid, and separating saidenantiomerically enriched α-arylcarboxylic acid from said protonatedcation of said amino acid, wherein said component is said protonatedcation of said amino acid.
 15. A process for preparing a salt of anamino acid and an α-arylcarboxylic acid of the formula Ar(R)CHCO₂ H,said process comprising distilling water from a mixture containing saidamino acid and said α-arylcarboxylic acid and then precipitating saidsalt from said mixture, wherein R is selected from the group consistingof C₁ -C₈ alkyl and C₁ -C₈ substituted alkyl; Ar is selected from thegroup consisting of phenyl, substituted phenyl, 2-naphthyl, substituted2-naphthyl, 2-fluorenyl, and substituted 2-fluorenyl; and said aminoacid is selected from the group consisting of lysine, arginine, andhistidine.
 16. The process of claim 15 wherein a water-immiscibleazeotroping agent is added to said mixture to assist said distillation.17. The process of claim 15 wherein said distillation produces adistillate containing two (2) liquid phases which are allowed toseparate and are then recycled independently.